Upper Right Coolant Pipe

Special tools and workshop equipment required

Removing

-- Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Fig 1: Identifying Engine Cover -Arrows-

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-- Remove the upper section of the intake manifold. Refer to Removal and Installation .

Fig 2: Identifying Bolts -Arrows-

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Vehicles Built through 05.10:

-- Disconnect the connector -3- on the intake flap motor -V157-.

Fig 3: Identifying Connector -3- And Bolts -4-

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-- Remove the bolts -4- and move the intake flap motor with the connecting rod -1- still attached to the side.

NOTE:

The connecting is not removed to avoid damage to the intake flap motor.

Ignore -2-.

-- Remove the bolt -1- and banjo bolt -3- for the oil supply line on the turbocharger.

Fig 4: Identifying Bolt -1-, Banjo Bolt -3-, And Turbocharger Oil Supply Line

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-- Move the oil supply line to the side.

NOTE:

Ignore -2-.

All Vehicles:

-- Disconnect the glow plug connectors for cylinders "1" and "2".

-- Free up the wiring harness on the right upper coolant pipe.

-- Disconnect and remove the coolant hoses and the 3094, to do this, loosen the hose clamps -arrows-.

Fig 5: Identifying Electrical Connector -1- And Hose Clamps -Arrows-

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-- Remove the right upper coolant pipe.

NOTE:

Ignore -1-.

Installing

Install in reverse order of removal. Note the following:

NOTE:

Secure all hose connections with hose clamps appropriate for the model.

-- Install the oil supply line. Refer to TURBOCHARGER OVERVIEW .

-- Intake flap motor and intake manifold upper section, installing. Refer to Removal and Installation .

-- Check the coolant level. Refer to CHECK THE COOLANT LEVEL .